Casting device



F. L. MOSIER CASTING DEVICE Dec. 27, 1966 Filed July 15, 1965 2 Sheets-Sheet il Dec. 27, 1966 F. MOSIER 3,294,220

CASTING DEVICE Filed July 15, 1965 2 Sheets-Sheet 2 j-cderc'zt flee! off/@6701 W14 6%, wat M 1 United States Patent Ofitlce 3,294,220 Patented Dec. 27, 1966 Deiaware Filed July 15, 1965, Ser. No. 472,241 4 Claims. (Cl. 199-1) This invention relates generally to casting apparatus and, more specifically, to an improved matrix assembly for use with a machine for casting bars or slugs of soft metal, particularly type-metal and similar alloys.

Cast slugs or bars of type-metal in which the faces of the desired characters are in relief or raised from a generally flat surface have been utilized in a variety of applications. Among these has been the production of rubber stamps by means of making from the slug a mold of Bakelite or similar plastic having recessions which correspond to the raised characters on the slug and in which rubber is formed into the shape of the desired rubber stamps. Another application of such cast slugs has been in relief or letter press printing where the raised faces of the characters on the slugs are inked so that their image is transferred to the printing medium upon contact. Generally, in slug casting machines used heretofore, matrices or recessed molds of the individual characters are assembled into a line, either mechanically or by hand, and the head of the slug with the characters in relief is formed by the solidification of molten metal disposed adjacent to the matrices and in their indentations. Utilizing a preferred type of casting apparatus, such as is manufactured by Ludlow Typograph Company of Chicago, Illinois under the name Ludlow, the matrices of individual characters are hand assembled into a line in a matrix holder or matrix stick and clamped against a surface of a mold having an inlet for molten metal. The matrix stick, the mold and the matrices define a space having in cross section the general shape of a T in which the slug is formed. Slugs produced in this manner utilizing matrices of individual characters generally have been limited to assemblies of discrete standard characters such as printed letters, punctuation marks, numbers and other mathematical symbols. It has been difficult using this method to produce slugs bearing signatures, patterns or other nnstandard characters.

When the printed matter is to be produced or the desired rubber stamp includes such non-standard elements it has been necessary to resort to the use of engraved or etched blocks or strips. For example, blocks have been engraved or etched with the pattern or signature in relief 7 and used in conjunction with slugs of type made by casting for direct printing or manufacture of Bakelite molds for rubber stamps. Alternatively, relatively thin strips have been engraved or etched with the pattern indented and used as matrices to produce cast slugs. In the latter case, it has been conventional to fasten such a strip to a blank matrix or matrices in a matrix stick by screws, a process which is inconvenient and time consuming. In either case, a slow and expensive process of engraving or etching the block or strip has been required.

Accordingly, a need has arisen for an improved means of producing slugs or bars bearing patterns or signatures in relief for use in producing rubber stamps and in letter press printing.

It is therefore an important object of this invention to provide an apparatus for producing slugs with patterns in relief which will not require etching or engraving in its operation.

A further object of the invention is to provide a casting device with which slugs bearing non-standard patterns may be quickly and economically produced.

- Another object of the invention is to provide an improved casting apparatus which is relatively simple in construction and operation.

Still another object of the invention is to provide an improved matrix assembly which may be utilized in conjunction with conventional slug casting machines for producing slugs bearing non-standard patterns.

Other objects and advantages of the invention will become apparent from the following description of an embodiment thereof, when considered in conjunction with the accompanying drawings in which:

FIGURE 1 is a plan view of the matrix assembly and portions of a casting machine showing certain features of the invention;

FIGURE 2 is an elevational view of the matrix assembly looking along the line 22 of FIGURE 1;

FIGURE 3 is a partially broken away perspective view of the matrix assembly and a slug;

FIGURE 4 is a vertical sectional view taken along the line 44 of FIGURE 1 and showing a portion of a casting machine, the improved matrix assembly and a slug in the position for casting; and

FIGURE 5 is a vertical sectional view taken along line 5-5 of FIGURES 1 and 4.

As shown in the accompanying drawings the present invention generally comprises a matrix assembly which includes a matrix 11, a matrix casing 12 and .a holding block 13 and which cooperates with a casting machine 14 having a mold 15 to form a T shaped slug 16 by support? ing the matrix and mold in fixed spaced relation and by confining molten metal between the matrix and mold.

; The matrix assembly 10 which will be more fully described hereinafter, is generally in the form of a flat, elongated, rectangular parallelepiped. The illustrated embodiment of the matrix assembly is especially adapted for use with the Ludlow casting machine previously mentioned, but it will be understood that the invention is not limited to such use and no unnecessary limitation is to be implied therefrom.

As illustrated, the casting machine 14 includes a housing having a generally horizontal top 17. Extending across the top is an elongated trough 18 having a flat bottom 19 and vertical sides 20, so that the top defines lodges 21 on each side of the trough on which the longitudinal edges of the bottom of the matrix assembly 10 may rest as will be hereinafter described. The trough 18 is further provided with a generally rectangular hole 22 centrally thereof, adjacent to which are disposed the operative parts of the casting machine 14 to be described herein.

Below the casting machine top 17 is a source (not shown) of molten type-metal which is connected to a mouthpiece 23 located below the hole 22 and having a longitudinal slot or aperture 24 parallel to the sides of the trough 18 through which the molten metal is forced upward. Securely mounted on top of the mouthpiece is the mold 15 having cooling means (not shown) for the molten metal and a longitudinal channel 27 which is generally vertically aligned with the slot 24 and in which the base or shank of the T shaped slug is formed. The mold 15 has a flat upper surface which cooperates with the matrix assembly 10 to provide a space for forming the head or crosspiece of the slug 15. The mouthpiece 22 and mold 15 normally are disposed slightly below the bottom of the trough 18 and in the hole 22, but are movable upwardly into contact with the matrix assembly in operation of the casting machine so that the upper surface of the mold is above the bottom 19 of the trough as shown in FIGURES 4 and 5.

Secured rigidly on the top 17, and spaced from one of the vertical sides of the trough 18, is a guide bar 28 having a vertical face which extends parallel to the side of the trough and against which one vertical longitudinal side of the matrix assembly rests in operation of the machine. Also, on the top 17 and on the opposite side of the trough adjacent to the hole 21 is disposed a locking bar or shoe 30 which is movable along the top at right angles to the sides 20 of the trough 18. The locking shoe 30 is connected to suitable locking means (not shown) whereby the locking shoe is moved into contact with the opposite longitudinal vertical side of the matrix assembly thereby forcing the matrix holder against the guide bar 28 so as to prevent horizontal motion of the matrix assembly 10 during the casting operation. A clamping bar 32 is suspended above the hole by suitable means (not shown) whereby the clamping bar is moved downward into contact with the top of the matrix assembly 10 at the same time the mold is moved upward and locked into such position so as to prevent vertical motion of the matrix assembly 10 during the casting operation.

The desired alignment of the matrix assembly 10 with the mold along the longitudinal dimension of the mold is accomplished by a stop arm 34 which is movable transversely to the trough 18 and is spring biased to engage a shoulder 36 on one side of the matrix assembly 10. As illustrated, the stop arm 34 is located at one end of the guide bar 28 preferably the end remote from the position of the operator of the casting machine. The stop arm 34 is mounted on a slide bar 38 which is movable in a channel (not shown) perpendicular to the sides of thetrough 18 thereby permitting the stop arm 34 to be removed from contact with the matrix assembly 10 so that the assembly may be moved past the position of the stop arm after the casting operation is completed.

Turning now to the design of the improved matrix assembly, as previously noted the matrix assembly 10 generally has the overall form of a flat, elongated, rectangular parallelepiped defined by the shape of the matrix casing 12. The matrix casing 12 is desirably made of steel and is provided with a rectangular central aperture 39 in which the matrix 11 may be disposed, and which extends between the top and bottom of the casing. A horizontal lip or flange 40 extends inwardly around the periphery of the aperture 39 on the bottom of the casing thereby providing a shelf for supporting the matrix 11. The flange 40 has a vertical edge 42 which, in the casting operation, defines the vertical edges of the head of the slug 16. The vertical edge 42 of the flange 40 is perpendicular to a horizontal lower face 44 which, as illustrated, extends longitudinally throughout the length and between the ends of the casing 12 and which, in the casting operation, is clamped against the flat surface of the mold 15. The lower surface 44 is narrower than the transverse dimension of the matrix casing and located centrally thereof so that a horizontal longitudinal surface 46 and a vertical longitudinal surface 47 are provided in each side of the bottom of the casing 12. The

lower surface 44 is also narrower than the trough 18 so that in operation, the surfaces 46 rest on the ledges 21 of the top 16 while the vertical faces 47 can touch the sides 20 of the trough 18, thereby providing a means for positioning the matrix assembly 10 over the trough when it is not adjacent the guide bar 28. The flange 40 and its vertical edge 42 are so dimensioned that the lower face 44 of the flange does not touch the bottom of the trough 18 when the matrix assembly is so positioned. The assembly 10 may thus be disposed with the surfaces 46 on the ledges 21 of the top 17 and easily slid into position over the hole 22 and the mold 15 prior to the time when the mold is raised into the casting position.

A handle 48 by which the assembly may be manipulated is attached to one transverse end of the matrix casing 12 by suitable means such as the illustrated threaded base 50 inserted in a threaded hole 52. The opposite end of the matrix casing from the handle 48 has at one side a recession or notch extending between the top and bottom of the matrix casing and terminating in the shoulder 36 which is perpendicular to the adjacent longitudinal side of the casing and which engages the stop arm 34 in operation of the device.

Disposed within the aperture 39 and resting on the flange 40 is the matrix 10. The matrix comprises a flat block having horizontal dimensions such as to provide a sliding fit with the walls of the aperture. The vertical dimension of the matrix 10 is preferably substantially less than the ditsance between the flange 40 on which the matrix rests and the top of the matrix casing 12. The mirror image of the pattern or signature which is to be produced in relief on the head of the slug 16 is recessed into the lower face of the matrix. The matrix is desirably formed of a material in which the pattern or signature may easily be carved by the point of a pantograph machine so that the signatures and other irregular patterns may be exactly reproduced. The material must also be able to withstand the high temperature caused by contact with the molten metal during the casting process. Materials which have been found to be satisfactory for many applications are Bakelite, manufactured by Union Carbide Corporation of New York City, New York, and Masonite, manufactured by Masonite Corporation of Chicago, Illinois. Matrices of these materials will, however, deteriorate after 10 to 15 casts are made; and, if more casts are contemplated in a particular application, it is pre* ferred to utilize matrices of a semi-soft metal, such as aluminum, or an alloy known in the art as Dowmetal. Also disposed in the aperture 39 and above the matrix 11 is the holding block 13. The holding block, which is desirably made of steel as is the matrix casing has horizontal dimensions which like those of the matrix permit a sliding fit of the block 13 in the aperture 39. The vertical dimension or thickness of the holding block is correlated with the thickness of the matrix so that when the two are placed in the aperture 39 with the matrix rest ing on the flange 40, the block will project above the surrounding upper face of the matrix casing 12. The purpose of this projection is to insure that, in operation, the clamping bar 32 will contact the holding block which, in turn, transmits the vertical clamping force to the matrix, thereby holding the matrix 11 rigidly in the desired position above the mold 15 during the casting operation.

The operation of the apparatus is as follows. A matrix is prepared having suitable overall horizontal and vertical dimensions to fit into the aperture 39 of the matrix casing 12 and having the desired pattern or signature recessed in one face. As previously noted, this may be accomplished by the use of a pantograph machine to exactly reproduce the pattern in a material such as Masonite or a metal matrix may be prepared by other processes such as casting if the matrix is to be used for a large number of casting operations. The matrix 11 is placed in the aperture 39 of the matrix casing 12 with its patterned side resting on the flange 40 and the holding block 13 is placed in the aperture on top of the matrix. The matrix assembly 10 is then positioned over the trough 18 by the operator with its horizontal surfaces 46 resting on the ledges 21 of the top 17. At this time the mold 15 and mouthpiece 23, the locking shoe 30 and the clamping bar 32 are all removed from the operative positions shown in FIGURES 4 and 5. The matrix assembly is caused to slide along the trough 18 and along the guide bar 28 until the shoulder 36 engages the stop arm 34 at which point the matrix assembly is above the hole 22. 7

With the shoulder 36 on the matrix casing 12 engaging the stop arm 34, the locking shoe 30 is moved into contact with the casing thereby locking the same against the guide bar 28 to prevent horizontal motion. At the same time, the mouthpiece 23 and mold 15 are moved upwardly into contact with the lower surface 44 of the flange 40, and the clamping bar 32 is moved downwardly to contact the holding block 13 thereby clamping the mold 15 and matrix assembly 10 together. Molten type-metal is then caused to flow through the slot 24 of the mouthpiece 23 into the space defined by the mold 15, flange 40 and matrix 11 thereby forming the slug with the mirror image of the indented pattern of the matrix produced in relief on its head. After the metal has hardened, the locking shoe 30 and clamping bar 32 are removed from contact with the matrix assembly 10, and the assembly is removed from the top 17. If desired, this may be accomplished by moving the slide bar 38 away from the trough thereby disengaging the stop arm 34 from the shoulder 36 so that the assembly may slide past the arm along the trough. Finally, the solidified slug is removed from the channel 27 in the mold 15 by means which are well known in the art.

It will be seen that the above described device makes possible rapid and economical production of slugs bearing non-standard patterns or signatures, since the time consuming and expensive processes of etching or engraving blocks or strips are eliminated by utilizing materials in which the pattern may be reproduced using a pantograph. Furthermore, the inconvenient process of screwing an engraved strip to a blank matrix is eliminated, thus increasing the productive time of the casting machine operator. As a result, slugs bearing signatures and other non-standard patterns may be produced in a shorter time and at less cost with the disclosed device.

Various changes and modifications may be made in the above described casting apparatus without departing from the present invention. For example, other specific materials could be utilized for the matrix and the matrix holder could be fabricated in a variety of forms which would fall within the spirit and scope of the present invention, various features of which are set forth in the accompanying claims.

I claim:

1. For use with a slug casting machine having means for supplying molten metal to a casting space, mold means comprising a portion of the walls of the casting space, and holding means for rigidly positioning a matrix assembly in contact with the mold means, an improved matrix assembly comprising a casing having an upper surface, a lower surface and an aperture extending between said upper and lower surfaces, said lower surface of said casing including 'a flange surrounding said aperture, a matrix fitting within said aperture and supported by said flange in spaced relation to the mold means so that said matrix and said flange cooperate with the mold means to define the casting space, said matrix having a vertical dimension less than the distance between said flange and the upper surface of said casing, and a holding block fitting within said aperture and lying against the upper side of said matrix, said holding block having a vertical dimension correlated with the dimension of said matrix so that the upper surface of said holding block projects above the upper surface of said casing and said holding block and the holding means cooperate to rigidly position said matrix in contact with said flange.

2. A matrix assembly having, in combination, a hollow rectangular casing having fiat top and bottom sides and a central rectangular aperture extending between the sides, a flange projecting inwardly around the periphery of said aperture on said bottom side of the casing, a matrix of flat rectangular shape lying against said flange and spaced thereby from said bottom casing side, said matrix substantially filling said aperture and having a thickness less than the spacing of said flange from said upper side of the casing, and a flat rectangular holding block substantially filling said aperture and lying against the upper side of said matrix, the combined thicknesses of said block and said matrix being greater than said spacing of said flange from said upper casing side whereby said block projects upwardly beyond such side for engagement by a clamping member.

3. For use with a slug casting machine having means for supplying molten metal to a casting space, mold means comprising a portion of the walls of the casting space, and holding means rigidly positioning a matrix assembly in contact with the mold means, an improved matrix assembly comprising a casing having an upper surface, a lower surface and an aperture extending between said upper and lower surfaces, said aperture being adapted to receive a matrix, said lower surface of said casing including a flange surrounding said aperture, said flange being adapted to support the matrix in spaced relation to the mold means so that the matrix and said flange cooperate with the mold means to define the casting space, and a holding block adapted to fit within said aperture and lie against the upper side of the matrix, said holding block having a vertical dimension correlated with the dimension of the matrix so that the upper surface of said holding block projects above the upper surface of said casing.

4. A matrix assembly comprising, in combination, a casing having top and bottom sides and an aperture extending between said sides for receiving a matrix, a flange projecting inwardly around the periphery of said aperture on said bottom side of said casing for supporting the matrix and a holding block adapted to fit in said aperture and lie against the upper side of the matrix, the combined thicknesses of said block and of the matrix being greater than the spacing of said flange from said upper casing side whereby said block projects upwardly beyond said upper casing side for engagement by a clamping member.

References Cited by the Examiner UNITED STATES PATENTS 2,652,145 9/1953 Lewandoski 199-47 X ROBERT E. PULFREY, Primary Examiner.

DAVID KLEIN, Examiner.

W, MCCARTHY, Assistant Examiner. 

1. FOR USE WITH A SLUG CASTING MACHINE HAVING MEANS FOR SUPPLYING MOLTEN METAL TO A CASTING SPACE, MOLD MEANS COMPRISING A PORTION OF THE WALLS OF THE CASTING SPACE, AND HOLDING MEANS FOR RIGIDLY POSITIONING A MATRIX ASSEMBLY IN CONTACT WITH THE MOLD MEANS, AN IMPROVED MATRIX ASSEMBLY COMPRISING A CASING HAVING AN UPPER SURFACE, A LOWER SURFACE AND AN APERTURE EXTENDING BETWEEN SAID UPPER AND LOWER SURFACES, SAID LOWER SURFACE OF SAID CASING INCLUDING A FLANGE SURROUNDING SAID APERTURE, A MATRIX FITTING WITHIN SAID APERTURE AND SUPPORTED BY SAID FLANGE IN SPACED RELATION TO THE MOLD MEANS SO THAT SAID MATRIX AND SAID FLANGE COOPERATE WITH THE MOLD MEANS TO DEFINE THE CASTING SPACE, SAID MATRIX HAVING A VERTICAL DIMENSION LESS THAN THE DISTANCE BETWEEN SAID FLANGE AND THE UPPER SURFACE OF SAID CASING, AND A HOLDING BLOCK FITTING WITHIN SAID APERTURE AND LYING AGAINST THE UPPER SIDE OF SAID MATRIX, SAID HOLDING BLOCK HAVING A VERTICAL DIMENSION CORRELATED WITH THE DIMENSION OF SAID MATRIX SO THAT THE UPPER SURFACE OF SAID HOLDING BLOCK PROJECTS ABOVE THE UPPER SURFACE OF SAID CASING AND SAID HOLDING BLOCK AND THE HOLDING MEANS COOPERATE TO RIGIDLY POSITION SAID MATRIX IN CONTACT WITH SAID FLANGE. 